scholarly journals A Thermal Model to Predict Tool Temperature in Machining of Ti–6Al–4V Alloy With an Atomization-Based Cutting Fluid Spray System

2017 ◽  
Vol 139 (7) ◽  
Author(s):  
Asif Tanveer ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Heat Transfer ◽  
Interaction Model ◽  
Spray Cooling ◽  
Droplet Surface ◽  
Cutting Fluid ◽  
Design Parameters ◽  
Transfer Model ◽  
Tool Temperature ◽  
Spray System ◽  
Heat Transfer Phenomenon

In this study, a heat transfer model of machining of Ti–6Al–4V under the application of atomization-based cutting fluid (ACF) spray coolant is developed to predict the temperature of the cutting tool. Owing to high tool temperature involved in machining of Ti–6Al–4V, the model considers film boiling as the major heat transfer phenomenon. In addition, the design parameters of the spray for effective cooling during machining are derived based on droplet–surface interaction model. Machining experiments are conducted and the temperatures are recorded using the inserted thermocouple technique. The experimental data are compared with the model predictions. The temperature field obtained is comparable to the experimental results, confirming that the model predicts tool temperature during machining with ACF spray cooling satisfactorily.

A Thermal Model to Predict Tool Temperature in Machining of Ti-6Al-4V Alloy With an Atomization-Based Cutting Fluid Spray System

2016 ◽  
Author(s):  
Asif Tanveer ◽  
Deepak Marla ◽  
Shiv G. Kapoor
Keyword(s):  
Heat Transfer ◽  
Interaction Model ◽  
Spray Cooling ◽  
Droplet Surface ◽  
Cutting Fluid ◽  
Design Parameters ◽  
Transfer Model ◽  
Tool Temperature ◽  
Spray System ◽  
Heat Transfer Phenomenon

In this study a heat transfer model of machining of Ti-6Al-4V under the application of atomization-based cutting fluid spray coolant is developed to predict the temperature of the cutting tool. Owing to high tool temperature involved in machining of Ti-6Al-4V, the model considers film boiling as the major heat transfer phenomenon. In addition, the design parameters of the spray for effective cooling during machining are derived based on droplet-surface interaction model. Machining experiments are conducted and the temperatures are recorded using the inserted thermocouple technique. The experimental data are compared with the model predictions. The temperature field obtained is comparable to the experimental results, confirming that the model predicts tool temperature during machining with ACF spray cooling satisfactorily.

Analytical Model for Heat Transfer Phenomena in Cup-Cast Method

2006 ◽  
Vol 116-117 ◽  
pp. 569-572
Author(s):  
Farshid Pahlevani ◽  
J. Yaokawa ◽  
M. Itamura ◽  
M. Kikuchi ◽  
O. Nagasawa ◽  
...  
Keyword(s):  
Heat Transfer ◽  
A356 Alloy ◽  
Nucleation And Growth ◽  
Heat Transfer Model ◽  
Solid Particles ◽  
Transfer Model ◽  
Heat Transfer Phenomenon ◽  
Semi Solid ◽  
Slurry Preparation ◽  
Good Agreement

Cup-cast method is a new method deals with semi-solid slurry preparation recently developed by the authors. In this method, suspension of globular solid particles in molten metal is prepared by controlling the nucleation and growth of solid-particles through the simplest and quickest techniques. In this method, heat transfer phenomenon plays an important role in governing the shape, size, and fraction of solid particles. In the current study, a heat transfer model was proposed and applied to Al-A356 alloy semi-solid slurry preparation. The heat transfer model was based on heat balance consideration between cup and slurry and it was in a good agreement with experimental results.

A Coupling Approach Combining Computational Fluid Dynamics and Finite Element Method to Predict Cutting Fluid Effects on the Tool Temperature in Cutting Processes

2019 ◽  
Vol 141 (10) ◽  
Author(s):  
Thorsten Helmig ◽  
Bingxiao Peng ◽  
Claas Ehrenpreis ◽  
Thorsten Augspurger ◽  
Yona Frekers ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Cutting Tool ◽  
Cfd Simulation ◽  
Cutting Conditions ◽  
Cutting Fluid ◽  
Tool Temperature ◽  
Aisi 1045 ◽  
Coupling Approach ◽  
Cutting Processes ◽  
Workpiece Setup

In metal cutting processes, the use of cutting fluids shows significant effects on workpiece surface quality by reducing thermomechanical loads on cutting tool and workpiece. Many efforts are made to model these thermomechanical processes, however without considering detailed heat transfer between cutting fluid, tool, and workpiece. To account for heat transfer effects, a coupling approach is developed, which combines computational fluid dynamics (CFD) and finite element method (FEM) chip formation simulation. Prior to the simulation, experimental investigations in orthogonal cutting in dry and wet cutting conditions with two different workpiece materials (AISI 1045 and DA 718) are conducted. To measure the tool temperature in dry as well as in wet cutting conditions, a two color pyrometer is placed inside an electrical discharge machining (EDM) drilled cutting tool hole. Besides tool temperature, the cutting force is recorded during the experiments and later used to calculate heat source terms for the CFD simulation. After the experiments, FEM chip formation simulations are performed and provide the chip forms for the CFD mesh generation. In general, CFD simulation and experiment are in reasonable agreement, as for each workpiece setup the measured temperature data are located between the simulation results from the two different tool geometries. Furthermore, numerical and experimental results both show a decrease of tool temperature in wet cutting conditions, however revealing a more significant cooling effect in a AISI 1045 workpiece setup. The results suggest that the placement of drilling holes has a major influence on the local tool temperature distribution, as the drilling hole equals a thermal resistance and hence leads to elevated temperatures at the tool front.

Evaluating Cutting Fluid Effects on Cylinder Boring Surface Errors by Inverse Heat Transfer and Finite Element Methods

1999 ◽  
Vol 122 (3) ◽  
pp. 377-383 ◽  
Author(s):  
Y. Zheng ◽  
H. Li ◽  
W. W. Olson ◽  
J. W. Sutherland
Keyword(s):  
Heat Transfer ◽  
Finite Element ◽  
Integral Transform ◽  
Heat Convection ◽  
Cutting Fluid ◽  
Transfer Model ◽  
Surface Error ◽  
Actual Surface ◽  
Surface Errors ◽  
Inverse Heat Transfer

Sets of dry and wet boring experiments are conducted to estimate the amount of heat transferred into the workpiece and the cutting fluid heat convection coefficient in a boring operation by an inverse heat transfer method. The temperature distribution in the bore is predicted using a heat transfer model that includes heat convection on the inner and outer bore walls. The developed model is solved by an integral transform approach. The thermal expansion of the bore is then calculated using the finite element method (FEM). Surface error due to the cutting forces is also predicted using FEM and added to the thermally induced surface error to give the total surface error. The actual surface error of bores machined under dry and wet cutting conditions are measured and compared with the predicted surface error. Very good agreement between measured and predicted surface errors is observed. [S1087-1357(00)00802-9]

scholarly journals Numerical investigation of the transient spray cooling process for quenching applications

2018 ◽  
Vol 22 (5) ◽  
pp. 1943-1953 ◽  
Author(s):  
Jakov Baleta ◽  
Fengsheng Qi ◽  
Marija Zivic ◽  
Martina Lovrenic-Jugovic
Keyword(s):  
Heat Transfer ◽  
Relevant Literature ◽  
Spray Cooling ◽  
Heat Transfer Process ◽  
Heat Transfer Model ◽  
Transfer Model ◽  
Wall Heat Transfer ◽  
Water Spray ◽  
Quenching Process ◽  
Particle Velocities

Water spray quenching distinguished itself as a promising method for industry production, especially for the parts which require good mechanical strength while simultaneously retaining the initial toughness. Studies have shown that the heat transfer process during the spray quenching is mostly influenced by the spray impingement density, particle velocities and sizes. The application of advanced numerical methods still plays insufficient role in the development of the production process, in spite of the fact that industry today is facing major challenges that can be met only by development of new and more efficient systems using advanced tools for product development, one of which is CFD. Taking the above stated, the object of this research is numerical simulation of spray quenching process in order to determine validity of mathematical models implemented within the commercial CFD code Fire, especially droplet evaporation/condensation and droplet-wall heat transfer model. After review of the relevant literature suitable benchmark case was selected and simulated by employing discrete droplet method for the spray treatment and Eulerian approach for the gas phase description. Simulation results indicated that existing droplet/wall heat transfer model is not able to reproduce heat transfer of dense water spray. Thus, Lagrangian spray model was improved by implementing experimental correlation for heat transfer coefficient during spray quenching. Finally, verification of the implemented model was assessed based on the conducted simulations and recommendations for further improvements were given.

Comparison of the Effects of Down Milling and Up Milling on the Tool Temperature in Machining of Ti-6Al-4V

2015 ◽  
Author(s):  
Jianfeng Ma ◽  
Changqing Qiu ◽  
Shuting Lei
Keyword(s):  
Heat Transfer ◽  
Temperature Distribution ◽  
Cutting Speed ◽  
Weight Ratio ◽  
Tool Material ◽  
Biological Properties ◽  
Heat Transfer Process ◽  
Depth Of Cut ◽  
Transfer Model ◽  
Tool Temperature

Ti-6AL-4V is widely used in the industry for the high strength-to-weight ratio at elevated temperature, its excellent resistance to fracture and corrosion, and biological properties. However, Ti-6AL-4V is hard to manufacture for its reactive chemical properties and low thermal conductivity that causes high temperature on the tool surface. Prediction of the tool temperature distribution from different manufacturing ways, up and down milling, has great significance in predicting tool wear pattern (cutting speed, feed/tooth, and axial depth of cut) in corner milling on temperature of the tool rake face. The tool material used is general carbide and Johnson-Cook plastic model is utilized to model the behavior of the workpiece Ti-6AL-4V. A separate Abaqus heat transfer model is used to analyze the heat transfer process after the tooth disengages the workpiece and before it engages the workpiece again to predict change of temperature distribution during this cooling process. The comparison of the up milling and down milling on the tool temperature is conducted.

Effects of Liquid Heat Dissipation on Heat Transfer Coefficient in Spray Cooling

2005 ◽  
Author(s):  
Shu-Ye Lei ◽  
Qiu-Min Lu
Keyword(s):  
Heat Transfer ◽  
Heat Flux ◽  
Heat Transfer Coefficient ◽  
Transfer Coefficient ◽  
Heat Dissipation ◽  
Strong Dependence ◽  
Spray Cooling ◽  
Complex Nature ◽  
Inlet Temperature ◽  
Transfer Model

The effects of the heat flux and liquid temperatures during spray cooling heat transfer were experimentally studied for non-boiling water spray cooling. The experiments show that the heat flux strongly affects the heat transfer coefficient, especially for high temperature sprays or low heat fluxes. A key effect is the heat dissipation from the liquid to the environment. The heat dissipation increases with the spray inlet temperature or the heat flux. To explain the strong dependence of the heat transfer on the heat dissipation in single phase, a spray cooling heat transfer model was suggested which includes the heat dissipation. Experimental measurements of the radial spray droplet temperature profile showed the complex nature of the heat dissipation.

Methodology to Characterize Heat Transfer Phenomena in Small Automotive Turbochargers: Experiments and Modelling Based Analysis

2014 ◽  
Author(s):  
J. R. Serrano ◽  
P. Olmeda ◽  
F. J. Arnau ◽  
A. Dombrovsky ◽  
L. Smith
Keyword(s):  
Heat Transfer ◽  
Standard Technique ◽  
Heat Transfer Model ◽  
Heat Fluxes ◽  
Experimental Methodology ◽  
Pollutant Emissions ◽  
Transfer Model ◽  
Great Effort ◽  
Heat Transfer Phenomenon ◽  
Comprehensive Study

These days great effort is devoted to the study of turbocharging in order to minimize fuel consumption and pollutant emissions of turbocharged reciprocating engines. Among all the processes taking place in small automotive turbochargers, the heat transfer phenomenon is one of the least analysed in a systematic way. However turbocharger heat transfer phenomena are very important at low engine loads. An accurate prediction of gas temperatures at turbine and compressor outlet and fluid temperatures at the water and oil outlet ports is not possible without considering heat transfer phenomena in the turbocharger. In the present work a comprehensive study of these phenomena is presented, showing their relevance compared to gas enthalpy variations through the turbomachinery. The study provides an experimental methodology to consider the different heat fluxes in the turbocharger and modelling them by means of a lumped capacitance heat transfer model. The input data required for the model is obtained experimentally by a proper combination of both steady and transient tests. These tests are performed in different test benches, in which compressible fluids (gas) and incompressible fluids (oil) are used in a given sequence. The experimental data allows developing heat transfer correlations for the different turbocharger elements. These correlations take into account all the possible heat fluxes, discriminating between internal and external heat transfer. In order to analyse the relative importance of heat transfer phenomena in the predictability of the turbocharger performance and the different related variables; model results, in hot and cold conditions, have been compared with those provided by the standard technique, consisting on using look up maps of the turbocharger. The analysis of these results evidences the highly diabatic operative areas of the turbocharger and it provides clearly ground rules for using hot or cold maps. In addition, paper conclusions advise about using or not a heat transfer model, depending on the turbocharger variables and the operative conditions that one desires to predict.

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